Energy Storage System Using

Regenerative Braking in an Electric Car

Final Year Project Proposal

GSN: Spring19-09

Group Members

Hamza Aslam 15-4485

Ehtesham Riazat 15-4502
Shah Zaman 15-4503

Advisor Sir Abdul Majid

Client Sir Abdul Majid

May 08, 2019

Department of Electrical Engineering

National University of Computer and Emerging Sciences, Lahore
 CERTIFICATIONS

This document has been prepared by all of us together and we take joint ownership of its
contents. We have provided references to the material consulted in preparing this document
and, to the best of our knowledge, have not plagiarized anything.

Hamza Awan, 15-4485 Date: May 08,2019

Ehtesham Riazat, 15-4502 Date: May 08,2019

Shah Zaman, 15-4503 Date: May 08,2019

I am the client of the product proposed in this document and the product specifications and
other details are according to my requirements.

Client:

Sir Abdul Majid Date: May 08,2019

The final year project proposal in this document is being submitted to the department of
Electrical Engineering with my approval.

Advisor:

Sir Abdul Majid Date: May 08,2019

Head of Department:

Dr. S. M. Sajid Date:

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Table of Contents
CERTIFICATIONS ...................................................................................................................................... 2
Chapter 1: Introduction .......................................................................................................................... 4
Chapter 2: Problem Definition ................................................................................................................ 5
(Client Requirements) ............................................................................................................................. 5
2.1 Problem Formulation ........................................................................................................................ 5
2.2 Record of Meetings with Client ........................................................................................................ 5
2.3 Preliminary Product Specification ..................................................................................................... 5
2.4 Expected Functionality of Product .................................................................................................... 5
Chapter 3: Problem Analysis ................................................................................................................... 7
3.1 Engineering Problem Model ............................................................................................................. 7
3.2 Recent Similar Projects ..................................................................................................................... 8
3.3 Distinguishing Features ..................................................................................................................... 8
3.4 Societal and Environmental Implications of the Project................................................................... 8
Chapter 4: Solution Design ................................................................................................................... 10
4.1 Design Requirements and Constraints............................................................................................ 10
4.2 Preliminary Design .......................................................................................................................... 10
4.2.1 Hardware Block Diagram ............................................................................................................. 11
4.2.2 Software Block Diagram ............................................................................................................... 12
4.3 Detailed Hardware and Software Design ........................................................................................ 13
4.3.1 Hardware Design.......................................................................................................................... 14
4.3.2 Software Design ........................................................................................................................... 15
Chapter 5: Deliverables and Cost .......................................................................................................... 17
5.1 Deliverables..................................................................................................................................... 18
5.2 Project Plan ............................................................................................................................... 18
5.3 Estimated Cost ................................................................................................................................ 18
5.4 Items to Purchase ........................................................................................................................... 19
References ............................................................................................................................................ 24

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Chapter 1: Introduction

This document describes our final year project. In this document our project is explained with
essential details and designing strategies used for it.

An electric car is a vehicle that uses motors for propulsion, using energy stored in rechargeable
batteries. Our final year project is to design a model electric car for proper utilization of the
electric energy stored in batteries. Braking is a tool that opposes the acceleration of moving
object. This is used to absorb the kinetic energy of moving object. In conventional braking
systems the electric energy is not utilized in well manner and a lot of kinetic energy is converted
into heat energy due to the friction between tyre and grasper of rotor and this heat energy is
then get wasted into the environment. Instead of losing that energy in the form of heat energy,
some part of it would be retrieved and stored back into batteries for further use. The
conventional braking system is not efficient so regenerative braking system will be used to
retrieve energy.
Basically regenerative braking system is technique to slow down the moving
vehicle using motor as brake. The basic principle of this braking system is the armature reaction
of motor. This would improve the overall efficiency of model electric car.

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Chapter 2: Problem Definition
(Client Requirements)

2.1 Problem Formulation

In conventional braking system of cars, brake pads get locked to the tyres and car stops due to
the friction between the tyres and brake pads. In this process the kinetic energy of the car is
converted into heat energy. This heat energy goes into the environment and cannot be
recovered. To solve this problem, regenerative electric brakes can be used to restore some
amount of energy consumed during the braking process.

2.2 Record of Meetings with Client

31/01/2019 Brief discussion about idea of project.
06/02/2019 Detailed discussion about idea and agreement for project.
28/02/2019 Discussion about components required.
13/03/2019 Explained him about progress.
17/04/2019 Showed him results of testing of basic circuit model.

2.3 Preliminary Product Specification

Our aim is to develop a model electric car with regenerative braking. The main components
required for a model electric car containing regenerative braking include a dc generator, a dc
shunt motor, 4 batteries (12V,2.5ah), a control unit consisting of a micro controller, relays etc.
It would also include the structure of a car .i.e. body of a car, tyres , steering wheel etc.

2.4 Expected Functionality of Product

The basic idea is that the control unit would switch between the DC motor and DC generator.
The DC motor would be used for acceleration and when brakes would be applied, the control
unit would switch the connection between the batteries and the DC motor to the batteries and

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the DC generator. DC generator (using armature reaction) would then be able restore the energy
into the batteries as well as to work as an electric brake due to its armature reaction.

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Chapter 3: Problem Analysis

3.1 Engineering Problem Model

Relevant Principle/Theory
Armature reaction is relevant principle used for this project. Armature reaction is basically the
effect of armature flux on the main flux (stator flux). When field winding are excited a main
field flux is produced which is linked with armature. Due to which a current flows through the
armature. This current produces another flux known as armature flux which lags the main field
flux. This armature flux eventually reduces the strength of main flux .i.e. demagnetizes the
main flux. Hence results into stoppage of rotation. (1905)
Retarding torque due to armature reaction is directly proportional to the armature current as
given by following equation :

This principle states that more the current drawn by the load results in more current passing
through armature which results in more distortion of main flux or retarding torque. This would
eventually stop the rotation in the DC generator.
The outcome of armature reaction seems appropriate to act as main principle behind the
regenerative brakes. After the connection between the batteries and the DC generator, armature
reaction would be used to finally stop the model electric car and the energy in the form of
electrical energy would be stored back into the batteries.

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3.2 Recent Similar Projects
A similar project on regenerative braking had been done by final year students of Seth Jai
Prakash Mukand Lal Institute of Engineering and Technology Haryana India. In this project,
regenerative braking is installed on a bicycle to light up safety flashers. Basic diagram as
available on their project report is given as:

(kango)

Basic block diagram of regenerative braking on a bicycle.

3.3 Distinguishing Features

Our project is based on a model electric car. It includes distinct components such as DC motor,
DC generator, control unit etc. More ever in our project, the energy retrieved would be stored
back into the main batteries.

3.4 Societal and Environmental Implications of the Project

Law of conservation of energy states that energy can neither be created nor destroyed, but it
can be converted from one form to another. Since energy cannot be produced by humans so it

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must be utilized as much as possible. This project is an attempt to maximize the use of energy
by converting the kinetic energy of a car into electrical energy and then restore it into main
battery for further use. Otherwise in conventional braking system, whole of kinetic energy is
converted into heat energy which goes into the environment and cannot be recovered. Impacts
of this project are that it saves energy and thus cost for recharging of batteries for a model
electric car. In this era of crisis, it is the need of the hour to utilize our resources in the most
effective way and do not waste them.

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Chapter 4: Solution Design

4.1 Design Requirements and Constraints

Our main purpose is to design a system to understand the phenomenon of regenerative braking
system on student level. To design this system we require a small vehicle, motor, electronic
control unit and batteries to store the extracted energy. We would build a model electric car
with regenerative braking system.
Regenerative braking only works on drive wheels. Regenerative brakes typically don’t provide
enough braking force under panic stop conditions. The friction brake is necessary back-up in
the event of failure of the regenerative brake. The efficiency of a regenerative system is limited
by factors like the capacity of the energy storage system and the output of the electric motor.

4.2 Preliminary Design

The main components we are going to use in our design are given as
 Motor
 Batteries
 Electronic Control System
During acceleration, the Motor/Generator unit acts as motor drawing electrical energy from the
batteries to provide extra driving force to move the car. During braking electric supply from
the battery is cut off by the electronic control system. As the car is still moving forward, the
Motor/Generator unit is act as electric generator converting car’s kinetic energy into electrical
and store in the batteries.
At Electronic Control System, the state of regenerative braking is controlled. Regenerative
braking itself means, as is well known, braking in which the operation mode of the electric
drive motor is changed over into an electric power generation mode, kinetic energy of the
driving wheels is recovered and the battery is then charged using the kinetic energy as electric
energy.

To control such regenerative braking, the Electronic Control System is provided with a storage
unit, a determination unit, a computing unit, and a command unit.

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4.2.1 Hardware Block Diagram

Regenerative occurs when the vehicle is in motion, such as coasting, traveling downhill or
braking. And the accelerator pedal is not being depressed. During this the motor becomes a
generator and sends energy back to the batteries. It is explained as follows, because the wheels
of a decelerating vehicle are still moving forward, they can be made to turn the electric motor,
which then feeds energy to the batteries for storage. The system becomes, in effect, a generator,
which provides braking force while it converts the vehicle’s kinetic energy into a reusable
form- electrical energy. When the accelerator pedal is released, the absence of pressure triggers
a response from the Energy Storage Unit which are in this case are batteries. Regenerative
braking begins, and the batteries are re-charged by the motor, which is turned by the wheels.
In this case, the friction brakes are not engaged. If more vigorous deceleration is required, and
the brake pedal is depressed, this engages both sets of brakes. However, to maximize energy
efficiency, it is advantageous to apply the regenerative brake as such as possible – it therefore
tends to do more of its total work in the first part of the braking motion. There are two
deceleration modes: 1. Foot off throttle but not on brake pedal – in this mode, the charge/assist
gauge will show partial charge, and the vehicle will slow down gradually. 2. Foot on brake
pedal - In this mode, a higher amount of regeneration will be allowed, and the vehicle will slow
more rapidly. During light brake pedal application, only the IMA motor//generator is slowing
the car. With heavier brake pedal application, the conventional friction brakes also come into
play. When decelerating, regeneration will continue until engine speed falls to about 1000 rpm.

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At this point, the driver will typically shift into neutral. In this way braking of the vehicle is
obtained.

file:///C:/Users/l154438/Downloads/btechmeprojectonregenerativebrakingsystem-
freepdfdownload-180721095339.pdf

4.2.2 Software Block Diagram

An “ON-OFF” engine control system is used. That means that the engine is “ON” until the
energy storage unit has been reached the desired charge capacity and then is decoupled and
stopped until the energy storage unit charge fall below its minimum requirement.

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Block diagram of Electronic Control Unit

4.3 Detailed Hardware and Software Design

During acceleration, the motor/generator unit acts as electric motor drawing electrical energy
from batteries to provide driving force to move the vehicle. During braking electric supply
from the battery is cut off by the electronic system.
An ON-OFF control system is used. Brake controllers are electronic device that can control
brakes remotely deciding when braking begins ends, and how quickly the brake need to be
applied. During the braking operation the brake controller directs the electricity produced by
the motor into the batteries.
In the Electronic Control System for the electric vehicle, battery unit acts as an electric energy
supply source. An electric motor (electric drive motor) which is supplied with electric power
from the battery unit and driving wheels are connected to a power output shaft of the motor via
a transmission. Arranged between the battery and the motor is an electric power conversion
circuit so that electric power from the battery is adjusted to a desired level through the electric
power conversion circuit and is then supplied to the motor.

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Further, the electric power conversion circuit is controlled through a motor controller.
According to this motor controller, a power output of the motor is controlled corresponding to
a stroke of an unillustrated accelerator pedal through the electric power conversion circuit. The
motor controller is internally provided with a regeneration control unit (controller).

At this regeneration control unit, the state of regenerative braking is controlled. Regenerative
braking itself means, as is well known, braking in which the operation mode of the electric
drive motor is changed over into an electric power generation mode, kinetic energy of the
driving wheels is recovered and the battery unit is then charged using the kinetic energy as
electric energy.
To control such regenerative braking, the regeneration control unit is provided with a storage
unit, a determination unit, a computing unit, and a command unit.
The determination unit performs a determination with respect to regenerative braking on a basis
of various information from the operation state detecting unit. From shift position information
from the shift position detecting unit, for example, the determination unit determines whether
the vehicle is in an advancing state or in a reversing state. Further, the computing unit performs
computation to control regenerative braking. This computing unit is provided with a
regenerative braking force calculation unit.
https://patents.google.com/patent/US6033041A/en

4.3.1 Hardware Design

In an electric system which is driven only by means of electric motor the system consists of an
electric motor which acts both as generator and motor. Initially when the system is cruising the
power is supplied by the motor and when the there is a necessity for braking depending upon
driver’s applied force on the brake pedal the electronic unit controls the charge flowing through
the motor and due to the resistance offered motor rotates back to act as a generator and the
energy is energy is stored in a battery or bank.
During acceleration, the Motor/generator unit acts as electric motor drawing electrical energy
from the batteries to provide extra driving force to move the car. With this help from the motor,
the car’s internal combustion engine that is smaller and with lower peak power can achieve
high efficiency. During braking electric supply from the battery is cut off by the electronic

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system. As the car is still moving forward, the Motor/ Generator unit is acts as electric generator
converting car’s kinetic energy into electrical and store in the batteries for later use.

4.3.2 Software Design

The algorithm for control unit is given as

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Calculations:
Following are the some of the basic formulation for the DC Shunt Motor:
 Relation between Torque and Armature Current: T  Ia a

 Relation between Speed and Armature Current: N E B


where : E B  V  I a Ra

 Relation between Speed and Torque:   V T  R A 2 T ind

K ( K )

Cicuit diagram of motor :

Equivalent Model of DC Shunt Motor

Chapter 5: Deliverables and Cost

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This Chapter includes explanation of estimated cost analysis and final deliverables of our
project. The project plan is also included that determines the working procedure with time
duration and human resource management about our project.

5.1 Deliverables
At the end of FYP-1 after the approval of advisor, the project report will be submitted to
department. At the end of FYP-2 our final product will be model electric car and its user
manual and fyp-2 report. Model electric car will be having all the functionalities mentioned
in our objective. The user manual will have instructions and rated conditions of the
equipment used in our project.

5.2 Project Plan

5.3 Estimated Cost

Our estimated cost analysis is in below table:

Component Name Quantity Price (Rs)

DC Motor (12V,120w,3350rpm) 9000

2
Battery (12v,2.5ah) 3000
4
Arduino 1 500

Tires 4 2000

LCD ( Hitachi HD44780 ) 2 800

Bluetooth Module (HC-05) 1 600

Structure (body,driver circuits etc.) 7000-8000

Rectifier Circuit 1 1500

Total 24400-25400

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This is our estimated cost analysis. This is almost final but some changes may affect this when
our hardware work starts. This estimate is based upon relative market prices but these prices
can be differ in future so this will also affect our project budget.

5.4 Items to Purchase

The items that will be purchased are:
 Electric motors:
Two electric motors will be used. One will act as motor and other will act as
an electric generator. DC shunt motor is selected because it is easy to control its speed.
The ratting of motor is:
o Voltage 12V
o Power 120w
o RPM 3350rpm

https://www.google.com.pk/search?q=DC+shunt+motor&rlz=1C1GCEU_enPK848PK848&source
=lnms&tbm=isch&sa=X&ved=0ahUKEwjyt-
qV7IviAhXl8KYKHeyqDDYQ_AUIDigB&biw=1920&bih=920#imgrc=Z1THgvTCZNgxzM:

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  Batteries:
As electric motors will be using energy stored in batteries so we will be using four electric
batteries for propulsion and regeneration purpose. Our selected battery ratting is as:

o Voltage 12V
o Ampere Ratting 2.5ah

https://www.google.com.pk/search?q=2.5ah+12v+battery&rlz=1C1GCEU_enPK848PK848&s
ource=lnms&tbm=isch&sa=X&ved=0ahUKEwiwgLT_8IviAhVH_qQKHQYMDH4Q_AUIDigB&bi
w=1920&bih=920#imgrc=Qvc4PWbkDk8TYM:
 Structure of car:
It includes the external structure of car. For this material will be
purchased.

 Drive shaft:
Drive shaft will be needed for the connection between tryes on both ends front
and back. The length of it will be decided later.

https://www.google.com.pk/search?q=drive+shaft&rlz=1C1GCEU_enPK848PK848&source=l

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 nms&tbm=isch&sa=X&ved=0ahUKEwjqmf3j84viAhVG2qQKHUQTBMwQ_AUIDigB&biw=192
0&bih=920#imgrc=3NOFp102vm67LM:
 Arduino:
Our control unit will be arduino.It will be controlling the working of motors and
braking process.

https://www.google.com.pk/search?q=arduino&rlz=1C1GCEU_enPK848PK848&source=lnm
s&tbm=isch&sa=X&ved=0ahUKEwjXubmA8oviAhUI2aQKHZLWAEEQ_AUIDigB&biw=1920&b
ih=920#imgrc=tyWNFG6xZWQw5M:
 Jumper wires:
A set of jumper wires to connect different circuit components will be purchased.

 LCD:
Hitachi HD44780will be used for displaying battery percentage and other important
features.

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 https://www.google.com.pk/search?rlz=1C1GCEU_enPK848PK848&biw=1920&bih=920&tb
m=isch&sa=1&ei=ZsjSXNSUBtKukwXShZMI&q=hitachi+hd44780+lcd&oq=Hitachi+HD44780+
&gs_l=img.1.0.0l3j0i30j0i24l6.207838.207838..209164...0.0..0.196.196.0j1......1....2j1..gws-
wiz-img.HrH-bSjBc3E#imgrc=BzsD8UeuCqlIzM:
 Bluetooth module:
HC-05 wireless bluetooth module will be used to control model electric car.

https://www.google.com.pk/search?q=HC-
05&rlz=1C1GCEU_enPK848PK848&source=lnms&tbm=isch&sa=X&ved=0ahUKEwjfupDz9ovi
AhXJjqQKHYFtC7QQ_AUIDigB&biw=1920&bih=920#imgrc=1W9wY8KzcQYXuM:

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  Rectifier circuit:
The rectifier circuit components will be purchased to recharge batteries. Its PCB will be
designed and it will be further used for recharging of batteries.

https://www.google.com.pk/search?q=rectifier+circuit&rlz=1C1GCEU_enPK848PK848&source=lnms
&tbm=isch&sa=X&ved=0ahUKEwjcyPOI-
IviAhWKsKQKHfzcAssQ_AUIDigB&biw=1920&bih=920#imgrc=MAhWolGSyGT-XM:

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References

 https://www.slideshare.net/Deepakkango/regenerative-braking-project-report
 https://www.quora.com/What-is-armature-reaction-in-dc-motor
 [2]Z. Guirong, Z. Henghai and L. Houyu, "The Driving Control of Pure Electric
Vehicle", Procedia Environmental Sciences, vol. 10, pp. 433-438, 2011.
 T. T. Vu, D. T. Lien, T. W. Chun, H. H. Lee, H. G. Kim and E. C. Nho,
"Development of low-cost drive system of a small-size electric vehicles," 8th
International Conference on Power Electronics - ECCE Asia, Jeju, 2011, pp.
1946-1949.
 Jones,W.D., "Hybrids to the rescue [hybrid electric vehicles]", IEEE Spectrum,
Vol. 40(1) , 2003, pp. 70 - 71.
 Aoife Foley, Brian O Gallachoir, Paul Leahy, Eamon McKeogh, "Electric
Vehicles and energy storage — a case study on Ireland", Vehicle Power and
Propulsion Conference 2009. VPPC '09. IEEE, pp. 524-530, 2009.
 https://s3.amazonaws.com/ppt-download/regenerativebrakingsystem-copy-
140322013044-phpapp02.pdf?response-content-
disposition=attachment&Signature=6mhXjU3CHbAhM6gJhj3CMWSxs5A%3D
&Expires=1556519004&AWSAccessKeyId=AKIAIA5TS2BVP74IAVEQ

Bibliography
(n.d.). Retrieved 05 06, 2019, from https://www.quora.com/What-is-armature-reaction-in-dc-motor

kango, d. (n.d.). slide share. Retrieved may 08, 2019, from

https://www.slideshare.net/Deepakkango/regenerative-braking-project-report

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